Hook-Shaped Floor Panel Coupling for Stable Downward Installation
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Solution Overview
Problem
Existing floor panels suffer from installation difficulties and insufficient locking strength due to suboptimal design of coupling parts, particularly in synthetic materials like polyvinyl chloride.
Innovation Solution
The floor panels feature hook-shaped coupling parts with specific positional relationships and geometries, including support surfaces, recesses, and guiding surfaces, which enhance vertical locking strength and ease of installation by allowing for elastic deformation during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional coupling parts are used in synthetic floor panels, then the floor panels can be assembled, but the locking strength is insufficient and installation is difficult
Solution Approach 1:
The coupling part is divided into functionally distinct segments: an upper hook-shaped part with a downward-directed locking element, a lower hook-shaped part with an upward-directed locking element, and intermediate locking parts with protrusions and undercuts. This segmentation allows each segment to perform its specific function optimally, with the hook-shaped parts providing vertical locking and the intermediate parts providing horizontal locking, thereby resolving the contradiction between locking strength and installation ease.
Solution Approach 2:
The coupling mechanism incorporates locking elements in multiple dimensions: vertical locking through the hook-shaped parts engaging in the vertical direction, and horizontal locking through protrusions and undercuts in the horizontal plane. This multi-dimensional locking approach simultaneously enhances locking strength in all directions while maintaining installation ease through the coordinated action of these dimensional elements.
2Ease of manufacture
If coupling parts are made integral with the substrate, then manufacturing is simplified, but the locking strength and stability are reduced
Solution Approach 1:
The coupling part is constructed as a composite structure combining the substrate material (synthetic material like polyvinyl chloride) with a separate coupling material that has superior mechanical properties for locking. The coupling part comprises a first material forming the substrate and a second material forming the coupling structures, where the second material provides enhanced strength and elasticity for the locking mechanism while the first material provides the base structural support.
3Adaptability or versatility
If the floor panels are made from synthetic materials like polyvinyl chloride, then manufacturing flexibility is improved, but the material deforms under temperature changes affecting locking stability
Solution Approach 1:
The coupling mechanism is designed to accommodate parameter changes in the synthetic substrate material due to temperature variations. The coupling part uses a material with different thermal expansion characteristics than the synthetic substrate, and the geometric design of the hook-shaped parts and locking elements allows for controlled movement and adjustment, maintaining locking stability despite thermal expansion and contraction of the floor panels.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The improved locking system provides strong and stable coupling while ensuring smooth installation, accommodating manufacturing tolerances, and reducing material deformation under temperature changes.
Implementation Method 1
The coupling part is formed of an elastic material and can be deformed in an assembled state
Implementation Method 2
the coupling parts, in the coupled condition of two of such floor panels, form a first locking system which effects a locking in a first direction in the plane of the floor panels, as well as form a second locking system which effects a locking in a second direction perpendicular to the edges and in the plane of the floor panels
Data Source
AI summary
A floor panel for forming a floor covering, wherein this floor panel is at least composed of a substrate; wherein the floor panel, on at least one pair of opposite edges, comprises coupling parts, which coupling parts allow that two of such floor panels can be coupled to each other by means of a downward movement of one floor panel in respect to the other floor panel; wherein these coupling parts, in the coupled condition of two of such floor panels, form a first locking system, which effects a locking in a first direction perpendicular to the plane of the floor panels, and form a second locking system, which effects a locking in a second direction perpendicular to the edges and in the plane of the floor panels.